4551 Rev 14551-20090309 10006 Santa Fe Springs Road Santa Fe Springs, CA 90670 USA Made in China Owner’s Manual and Operating Instructions SAVE THESE INSTRUCTIONS Important Safety Instructions are included in this manual 4500 lb.
Table of Contents Introduction ..................................... 1 Accessories................................................ 1 This Booklet .............................................. 1 Manual Conventions ......................... 2 Safety Rules ...................................... 3 Controls and Features ....................... 5 Winch ........................................................ 5 Mounting .......................................... 6 Operation .......................................
Introduction Introduction This Booklet Every effort has been made to ensure the accuracy and completeness of the information in this manual. We reserve the right to change, alter and/or improve the product and this document at any time without prior notice. Congratulations on your purchase of a Champion Power Equipment winch. CPE designs and builds winches to strict specifications. With proper use and maintenance, this winch will bring years of satisfying service.
Manual Conventions Manual Conventions CAUTION This manual uses the following symbols to help differentiate between different kinds of information. The safety symbol is used with a key word to alert you to potential hazards in operating and owning power equipment. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Follow all safety messages to avoid or reduce the risk of serious injury or death.
Safety Rules Safety Rules WARNING WARNING Do not move the vehicle to pull a load (towing) on the winch cable. This could result in cable breakage. Read this manual thoroughly before operating your winch. Failure to follow instructions could result in serious injury or death. WARNING WARNING Pull only on areas of the vehicle as specified by the vehicle manufacturer Do not exceed the rated capacity. WARNING DANGER Do not use this winch for lifting or moving people or animals.
Safety Rules WARNING Batteries contain acid and produce explosive gases. Keep sparks, flames and cigarettes away from batteries at all times. Wear safety glasses and protect the eyes at all times. Do not lean over the batteries during operation. WARNING When re-spooling the cable, ensure that the cable spools in the under-wind position with the cable entering the drum from the bottom, not the top.
Controls and Features Controls and Features Read this owner’s manual before operating your winch. Familiarize yourself with the location and function of the controls and features. Save this manual for future reference. Winch (1) Motor: 1.6 HP 12V DC motor provides power to the planetary gear mechanism. (2) Braking System: Braking action is automatically applied to the winch drum when the winch motor is stopped and there is a load on the wire rope.
Mounting Mounting This CPE 4,500 lb winch is designed with a bolt pattern that is standard in this class of winch. Many winch mounting kits are available that utilize this bolt pattern for the most popular trucks, SUV’s and ATV’s. If you cannot find a kit locally, contact CPE and we will provide you with the name of a dealer near you. CAUTION Mounting bolts must be SAE grade 5 or better and torque to 34 ft. lbs. 1.
Operation Operation General Tips for Safe Operation Your 40252 winch is rated at 4,500 lbs. capacity in first layer (max) when spooling the first rope layer on the drum. Overloads can damage the winch, motor and/or wire rope. For loads over 2,000 lbs. we recommend the use of the pulley block/snatch block to double the wire rope line. The will aid in two ways: a) reduce the number or rope layers on the drum, as well as, b) reduce the load on the wire rope by as much as 50%.
Operation Winching Techniques A-Z a. Take time to assess your situation and plan your pull. b. Put on gloves to protect your hands. c. Disengage the clutch to allow freespooling and also save battery power. d. Attach the hook strap to the clevis hook. e. Pull out the wire rope to your desired anchor point using the hook strap. f. Secure the clevis hook to the anchor point: Sling, chain or snatch block. Do not attach the hook back onto the wire rope. g. Engage the clutch. h.
Maintenance Maintenance The owner/operator is responsible for all periodic maintenance. WARNING Lubrication All moving parts within the Electric Winch having been Lubricated using high temperature lithium grease at the factory. No internal lubrication is required. Lubricate Cable Assembly periodically using a light penetrating oil. Never operate a damaged or defective winch. Cable Assembly Replacement WARNING Improper maintenance will void your warranty.
Specifications Specifications Performance Specifications Rated Pull Gear Reduction Ratio Motor 4,500 lb (2041 kg) 166:1 Permanent Magnet 1.6 HP/(DC 12V) Duty Cycle Intermittent Drum Size 2” (D) x 4.92” (L) 50.8 mm (D) x 125 mm (L) Cable 7/32” (D) x 52’ (L) 5.4 mm (D) x 16 m (L) Weight 34.9 lb. (15.8 kg) Height 5.0 inches (127 mm) Width 4.55 inches (115.5 mm) Length 16.3 inches (415 mm) Bolt Pattern 6.
Specifications Winch Diagram Rev 14551-20090309 11
Specifications Winch Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 12 Part Number 450100 450001 450002 450003 450200 450004 450005 450006 450007 450008 450009 450010 450300 250002 450011 450012 450013 450014 450015 450016 450017 450018 450019 450400 450020 300900 450021 300020 300019 450022 450023 250036 450024 450500 300022 450025 450026 450027 Description Motor Assembly Coupling, I Spring, Coupling Coupling, II Drum Assembly Gea
Troubleshooting Troubleshooting Problem Motor does not turn on Cause Switch Assembly not connected properly Loose battery cable connections Solenoid malfunctioning Solution Insert Switch Assembly all the way into the connector. Tighten nuts on all cable connections. Tap solenoid to loosen contacts. Apply 12 volts to coil terminals directly. A clicking indicates proper activation. Defective Switch Assembly Defective motor Replace Switch Assembly. Check for voltage at armature port with Switch pressed.
Warranty Warranty CHAMPION POWER EQUIPMENT ONE YEAR LIMITED WARRANTY Effective September 1, 2006. Replaces all undated warranties and all warranties dated before September 1, 2006. Warranty Qualifications Champion Power Equipment (CPE) will register this warranty upon receipt of your Warranty Registration Card and a copy of your sales receipt from one of CPE's retail locations as proof of purchase.
Warranty This warranty gives you certain legal rights which may change from state to state. Your state may also have other rights you may be entitled to that are not listed within this warranty. Contact Information Address Champion Power Equipment, Inc. Customer Service 10006 Santa Fe Springs Rd. Santa Fe Springs, CA 90670 Rev 14551-20090309 Customer Service Mon – Fri 8:30 AM – 5:00 PM (PST/PDT) Toll Free: 1-877-338-0999 Fax no.
Notes Notes 16 Rev 14551-20090309
